* FZ ate E \ 3 + S * oo thes CETOP RE-2004.01/H HYDRAULICS PROGRAMME (H1) CETOP (PASSPORT) OCCUPATIONAL LEVEL 1INTRODUCTION This is the LEVEL 1 Hydraulics (H1) Programme, forming the start of a series of competence-based qualifications designed around CETOP occupational levels, It combines the necessary knowledge and competence based skills for those people on route to a higher level qualification at levels 2 and 3, involving the maintenance and management of both Industrial and Mobile hydraulic systems. Note: In all cases, each programme represents a “stand-alone” qualification but can also be a progressive route to a higher level. QUALIFICATION MODEL FOR HYDRAULICS Mobile Hydrauli Industrial Hydrauli MOBILE HYDRAULICS ‘MHS (LEVEL 3) = MOBILE HYDRAULICS ‘MH (LEVEL 2) POWER HYDRAULICS HI (LEVEL 1) INDUSTRIAL HYDRAULICS & ASSOCIATED CONTROL TH (LEVEL 3) f INDUSTRIAL HYDRAULICS TH2 (LEVEL 2) CETOP OCCUPATIONAL LEVELS LEVEL (1) This person will perform activities that follow an established procedure. Activities wil be recurring and of a short-term nature. ‘The reaction to most problems will be to summon help follow a predefined set of actions. LEVEL (2) This person will perform a variety of activities needing some understanding of the technical factors involved. The activities may require the interpretation and application of varied and non-routine specifications. Activities will involve the use of simple diagnostic checks and ability to make a positive response to deviations. Co-operation with others in team or work groups may be required. LEVEL (3) This person will be involved in a broad and often complex range of activities, often requiring independent decisions to be made on technical matters concerning specifications, resources or processes. Planning of work will be a responsibility, as will the finding and rectification of faults. ility for the quality of work undertaken and the required outcomes are also included,LEVEL (4) This person will be competent in a broad range of complex, technical or professional work activities performed in a wide variety of contexts and with a substantial degree of responsibility and autonomy. Responsibility for the work of others and allocation of resources is also involved This level 1 programme provides an excellent introduction to power hydraulics and places great emphasis on the understanding of fundamental principles, component funetionality and principles of operation, Emphasis upon health and safety and that of developing safe working practices is applied throughout, asa CORE ELEMENT within the scheme. CORE ELEMENTS are not necessarily taught as specific subject areas but integrated within the scheme, Methodology and Assessment The programme can be offered via a range of learning modes devised by the approved centres ranging from that of short courses to distance learning and centre based modules. ‘The timescale can also be flexibly managed by the approved centres. Candidates will be expected to complete a series of written assignments throughout the programme of study to re-inforce the leaming process. These can be supportive to the final marks for the knowledge-based section. Assessment will consist of: (a) Awritten examination of 2 hours minimum duration with a pass mark of 60%. (b) Practical task competence based unit assessment will be carried out on a “one to one” basis, candidate to tutor, on a pass/fail basis, against agreed evidence of performance. No part of this publication may be photocopied or otherwise reproduced without the prior p. in writing of the Association. ssion Whilst the Association does its best to ensure that any information it may give is accurate, no liability or responsibility of any kind is accepted in this respect by the Association, its members, its servants or agents, Pdf version of this document can be obtained from the CETOP website : www.cetop.org E-mail: education @cetop.org © 2004When assessing competence the following processes must be followed: 1. Relating to the occupational level a series of Assessed Abilities are identified. These represent the “DOING PART” of a person’s job and requires a combination of both practical skills and applied knowledge 2. For each Assessed Ability, evidence of performance is then established and shown as EVIDENCE REQUIRED (sometimes termed performance criteria), In alll cases candidates must meet the requirements of each Assessed Ability. During practical task assessment the ASSESSOR will agree the “type of evidence” to be obtained and this can range from: * Direct Observation * Verbal Questioning/Candidate Commentary © Written Report and may include all types, Assessment Requirements Assessed Ability P1.1 Recognise the component parts of a selected machine and their functionality, linked to system and circuit diagram. Evidence Required HI.1.1 — Reservoir and associated parts identified including functionality. HI.1.2 Pump type identified and associated connections. H1.1.3 Method used for controlling pressure identified. HI.1.4 Method used for controlling flow identified. HILLS Actuator type identified. H1.1.6 Filter location identified and associated filter performance indicator. Assessed Ability H1.2_ From cireuit diagram provided and associated systen strategic points and record. -ck operating pressures at Evidence Required HI.21 Safety checks carried out before pressure checks commence and working environment assessed, H1.2.2 Test points identified on circuit diagram and machine system, check list established. H1.2.3 Correct range of pressure gauges and connections used at all times HL2.4 Pressure readings taken and recorded. H1.2.5 Safe working practices followed at all times. HL.2.6 Written report completed covering all findings.Assessed Ability H1.3 Change filter element on a system. HI3.1 H13.2 H133 W134 H13.5 H13.6 H13.7 HL Evidence Required Risk assessment check carried out and working procedures established. Specification of new element checked against machine specification (element part number) type and size. Correct isolation procedures followed before dismantling process commenced. Correct tools used at all times. Cleanliness control procedures followed and spillage of oil prevented at all times. Filter disposal procedures established. Operational checks carried out after installation (system left and environment “ purpose”). Assessed Ability Check accumulator pre-charge pressure and establish level against spec Evidence Required HL4.1 Established procedures followed at all times. H1.4.2 Safe working practices followed at all times. HL4.3 Correct tools and test equipment used. HL.4.4 Written report completed covering all actions taken.KNOWLEDGE BASED UNIT (11) CONTENTS HL5.1 Fundamental Principles. H1.S.2_ Hydraulie System Construction (BASIC BUILDING BLOCKS). HL5.3 Components — function and operation, HLLS5.4_— Hydraulic Fluids. HLS. Cleanliness Control, HL5.6 First Line Management. HLS.7 Maintenance Procedures. © Health and Safety CORE ELEMENT © Do's and Don'ts © Good/Safe Working Practices/Risk Assessments © Literacy and Numeracy CORE ELEMENT ¢ Use of Basic Formula Application of Simple Calculations and Associated Units * Terminology KNOWLEDGE BASED UNIT — WRITTEN EXAMINATION SPECIFICATION The examination paper will contain questions from the 7 sections of this programme and core elements will be integrated as necessary. * Examination minimum duration 2 consecutive hours # Pass mark 60% * Question style may be single subject, multiple subject, short answer and multiple choiee Where calculations and formulae are involved, all progressive stages of the calculation together with their corresponding units must be shown.HYDRAULIC (Knowledge Based Unit) HL5S.1 Fundamental Hydraulic Principles @ (b) ©) Know the fundamental principles that underpin the operation of all hydraulic systems and how they affect performance: = flow makes it go = pressure provides the pushing force 7 oil in a system always takes the path of least resistance - pressure is a measure of the resistance to flow - for oil to flow in any system, there has to be a pressure difference = the greater the pressure drop the greater the flow potential = when fluid flows from a high pressure level to a lower pressure level and no work is carried out, then heat is generated State and use the relationship between: = pressure, area and the force transmitted by a cylinder = flow rate, cylinder dimensions and cylinder velocity = pressure, displacement and hydraulic motor torque = flow rate, displacement and motor speed ~ pump displacement, shaft speed and flow rate - pump flow rate, operating pressure and hydraulic power ~ volumetric efficiency, mechanical efficiency and overall efficiency of pumps and motors - pipe diameters, flow rates, fluid viscosity and pressure losses Know the units and terminology relating to: = flow rate = speed + pressure - temperature = power - torque ~ motor and pump sizes HL5.2 Hydraulic System Construction and Symbolic Representation @ (b) Know the component parts used to construct a hydraulic system and the basic layout (basic biulding blocks). Outline the function of the component parts used to construct a hydraulic system relating to: - prime mover ~ coupling and bell housing - pumps = reservoir~ filters - pipes rigid and flexible - relief valves ~ pressure reducing valves - direction control valves = flow control valves + hydraulic motors - hydraulic cylinders + pressure gauges = flow meter = check valves- inline and pilot operated = bladder (bag) accumulator (© Recognise and use current graphical hydraulic symbols to represent the component parts of'a hydraulic system. (ISO 1219-1). H15.3 Operation of the Major Components used to construct a Hydraulic System (a) Describe the operating principles of the following components: = gear pump (external) = yane pump (cartridge type) = piston pump (swash plate — pressure compensated) + relief valve (direct and pilot operated) = pressure reducing valve = direction control valves (lever operated and solenoid operated) = pilot operated check valve = throttle valve (with and without free flow check valve) = pressure compensated flow control valve filter with bypass and differential indicator - hydraulic motor (piston and orbit) = eylinders (tie rod and serewed body types) - cylinder cushioning = accumulator and safety block. 11.5.4 Hydraulic Fluids and their Characteristics (a) Know the meaning of the following terms: ~ viscosity + 180 viscosity grade () Know the function of the hydraulic fluid: = power transmission = lubrication = cooling = carrying contaminants to the nearest filterHLS HIS.6 (©) Outline the effet of system temperature on: ~ oil viscosity and system performance (a) Know the factors that affeet the life of the hydraulic fluid and their effeet upon system performance: contamination - heat = moisture (@) Know the origin of contamination and ways in which it enters a system () Outline procedures to follow to reduce contamination ingression (©) Know the effects of contaminants on the life and performance of component parts. (d) Know the locations of filters within a system. () Outline the performance of a filter, including by-pass and indicator. (f) Know the importance of regular fluid contamination analysis and the correct interpretation of the results, First Line Management of Hydraulic Systems (a) Know the points of inspection and the observations to be made: (1) Power unit and prime mover: i) Stop — Start — Isolation ii) general external cleanliness iii) position and security of all guards iv) relevance of all not k assessment v) _ noise level and general temperature vi) hydraulic oil level and colour at sight glass vii) suction hose connections and hose conditions pressure gauge readings signs of leakage security of fittings — pipes and hoses filter indicator status reservoir access points and sealing arrangements accumulator inspection and associated safoty block (pre-charge pressure checks) xiv) general structure of power unit (steel work)(2) Hydraulic System: i) operation of services (feedback from operator) ii) leakage (cylinders, motors, hoses, sub-plates and stacks) view topping up record iii) _ pressure readings inline with operating specification iv) noise and vibration v) system filter and indicator status (b) Know how to effectively complete a written report covering: = non compliances = actions taken = request for fixther investigation HLS.7 intenance Procedures (a) Know the requirements of a pro-active maintenance programme with reference to health and performance monitoring and relating to: - pump performance testing (QP) - periodically taking pressure readings under varying operational conditions - taking regular oil samples to enable cleanliness level to be assessed - taking regular oil samples to determine oil life expectancy - checking systems temperatures - checking working performance (time based operations) (b) Know how to effectively complete a written report covering: = non compliances . results identified = actions taken = request for further investigation